Modeling and simulation of material distribution in the sequential co-injection molding process

In co-injection molding,the properties and distribution of polymers will affect the application of products.The focus of this work is to investigate the effect of molding parameters on the skin/core material distribution based on three-dimensional(3-D)flow and heat transfer model for the sequential coinjection molding process,and the flow behaviors and material distributions of skin and core melts inside a slightly complex cavity(dog-bone shaped cavity)are predicted numerically.The governing equations of fluids in mold are solved by finite volume method and Semi-Implicit Method for Pressure Linked Equations(SIMPLE)algorithm on collocated meshes,and the domain extension technique is employed in numerical method for this cavity to assure that the numerical algorithm is implemented successfully.The level set transport equation which is used to trace the free surfaces in co-injection molding is discretized and solved by the 5 th-order Weighted Essentially Non-Oscillatory(WENO)scheme in space and 3 rd-order Total Variation Diminishing Runger-Kutta(TVD-R-K)scheme in time respectively.Numerical simulations are conducted under various volume fraction of core melt,skin and core melt temperatures,skin and core melt flow rates.The predicted results of material distribution in length,width and thickness directions are in close agreement with the experimental results,which indicate that volume fraction of core melt,core melt temperature and core melt flow rate are principal factors that have a significant influence on material distribution.Numerical results demonstrate the effectiveness of the 3-D model and the corresponding numerical methods in this work,which can be used to predict the melt flow behaviors and material distribution in the process of sequential co-injection molding.

Effect of Molecular Weight and Molecular Distribution on Skin Structure and Shear Strength Distribution near the Surface of Thin-Wall Injection Molded Polypropylene

In this study, the relationship between skin structure and shear strength distribution of thin-wall injection molded polypropylene (PP) molded at different molecular weight and molecular distribution was investigated. Skin-core structure, cross-sectional morphology, crystallinity, crystal orientation, crystal morphology and molecular orientation were evaluated by using polarized optical microscope, differential scanning calorimeter, X-ray spectroscopic analyzer and laser Raman spectroscopy, respectively, while the shear strength distribution was investigated using a micro cutting method called SAICAS (Surface And Interfacial Cutting Analysis System). The results indicated that the difference of molecular weight and molecular weight distribution showed own skin layer thickness. Especially, high molecular weight sample showed thicker layer of the lamellar orientation and molecular orientation than low molecular weight sample. In addition, wide molecular distribution sample showed large crystal orientation layer.

Numerical simulation of temperature and strength distributions of mold(core) on heating

By using Visual C++, a model with post processing was carried out to simulate the temperature and strength distributions of the mold(core). The results are shown in 256 color graphic mode. With this model, the temperature and strength distributions of the mold(core) both in case of heating process for core in the furnace and solidification process for a thin wall aluminum alloy casting in the mold(core) are numerically simulated. The results show that the temperature and strength distributions of the mold(core) were uneven because the thermal conductivity of the resin sand was much small. This study laid a basis for the optimum design of the mold(core) properties. [

The Influence of Molding Density of TiO2 Varistor-Ceramic on Densification of Ceramic Body and Grain Growth

This article explored the influence of molding density of TiO2 varistor-ceramic on densification of ceramic body and grain growth. By the main phase and second phase analysis of TiO2 varistor-ceramic through XRD and EDAX, the effects of the second phrase on TiO2 varistor-ceramic were studied. Grain size and its distribution were observed through scanning electron microscope and the density of porcelain body was measured. The effects of grain size, distribution and density of ceramic body on electrical property of TiO2 varistor-ceramic were the focus issue for analysis. The increased molding density would improve the densifying of magnetic body to some extent and promote grain growth.

The Relationship between Bulk Property and Property Distribution in Thin-Wall Injection Molded PP at Different Molecular Weight and Molecular Weight Distribution

Thin-wall injection molded parts have been paid much attention to the lightweight saving from viewpoints of natural resources saving. In the injection molding, skin-core structure can be found in the parts. This skin-core structure affects the property of completed injection molding parts (bulk property) even if in thin-wall injection molding. However, there is a few research about the relationship between bulk property and internal property distribution in the injection molding specimen. In this study, thin-wall injection molded parts of polypropylene (PP) were prepared by 4 different molecular weight and molecular weight distribution to reveal the relationship between bulk property and property distribution. These characteristics were investigated by using tensile test, fracture toughness characterized by Essential Work of Fracture (EWF) method for bulk property and film tensile test by sliced sample for tensile property distribution. The property distribution test results revealed that the highly bulk property sample had thicker highly mechanical property layer on its surface.

Distribution and engulfment behavior of TiB_2 particles or clusters in wedge-shaped copper casting ingot

Wedge-shaped copper casting experiment was conducted to study the engulfment behavior of TiB2 particle and the interaction between particle or cluster and the solid/liquid front in commercial pure aluminum matrix. The experimental results show that the particle size distribution obeys two separate systems in the whole wedge-cast sample. Furthermore, it is found that the big clusters are pushed to the center of the wedge shaped sample and the single particle or small clusters consisting of few particles are engulfed into the α-Al in the area of the sample edge. The cluster degree of particles varies in different areas, and its value is 0.2 and 0.6 for the cluster fraction in the edge and in the center of the wedge sample, respectively. The cluster diameter does not obey the normal distribution but approximately obeys lognormal distribution in the present work. More importantly, in the whole sample, the particle size obeys two separate log-normal distributions.

Parameter Prediction of Stretch-Blow Molding Process of PET Using Neural Networks

This study presents a parameter selection strategy developed for the Stretch-Blow Molding (SBM) process to minimize the weight of preforms used. The method is based on a predictive model developed using Neural Networks. The temperature distribution model of the preform was predicted using a 3-layer NN model with supervised backpropagation learning. In addition, the model was used to predict the uniform air pressure applied inside the preform, taking into account the relationship between the internal air pressure and the volume of the preform. Parameters were validated using in situ tests and measurements performed on several weights and lengths of a 0.330 Liter Polyethylene Terephthalate (PET) bottles. Tests showed that the model adequately predicts both the blowing kinematics, mainly zone temperatures and blowing and stretching pressures along the walls of the bottle while maintaining the bottle strength and top load requirements. In the second step, the model was combined to automatically compute the lowest preform weight that can be used for a particular 330 ml bottle design providing a uniform wall thickness distribution.

Thickening and Rheological Properties of Crystalline Polyester Used in Low Pressure Sheet Molding Compounds

Low pressure sheet molding compound （LPMC,1.0-3.0 MPa,95-103 ℃） is a new kind of thermosetting material with crystalline polyester as a physical thickenner.LPMC is different from conventional SMC using an earth oxide thickening agent （e.g.MgO） as chemical thickenner,it relies on the physical thickening of crystalline polyester.Crystalline polyester resin is the key material to mold LPMC parts.Currently there was no report about the thickening mechanism of crystalline polyester in LPMC.In this article,crystalline polyester resins,whose melting points were between 45 ℃ and 89 ℃,were synthesized by a two-step esterification.The melt points of crystalline polyesters are controlled by regulating the mol ratio of the two glycols and the two acids.And by means of varying the content of crystalline polyester resin,the thickening effect on resin paste is investigated.In addition,the thickening mechanism of crystalline polyester in LPMC was investigated by FTIR and DSC analysis.The effects of the diameters and viscosity of crystalline polyester on the rheological property and fiber distribution of LPMC sheets were studied,too.Results show that the thickening effect is excellent when the weight content of crystalline polyester resin is 3%.And there exists three kinds of functions acting in the process of thickening：swelling,hydrogen bonds and induction crystallization.During the preparing process of resin paste in LPMC,the temperature of resin paste must be kept at 90 ℃.In addition,crystalline polyester make LPMC have a perfect fluid property.When the viscosity of LPMC sheet is beyond 1 kPa s,the fiber orientation is not obvious.But when the viscosity of LPMC sheet is about 500 Pa s,the fiber shows a certain degree of orientation.Moreover the study of physical and chemical thickening mechanism of crystalline polyester and the rheological discipline of LPMC sheets in the hot mould will provide the researchers and enterprises with theory guidance.

纳米增强超高韧性混凝土纤维分布及弯曲性能

为探究纳米SiO_(2)掺量与成型工艺对超高韧性混凝土(STC)弯曲性能的影响,制备了4种不同纳米SiO_(2)掺量的STC,通过四点弯曲试验研究了薄层夯捣和常规浇筑2种不同成型工艺下STC的弯曲性能,并结合CT细观测试分析了STC内纤维的取向分布,探讨了弯曲性能与纤维取向之间的关系。结果表明,不同纳米SiO_(2)掺量下,经薄层夯捣的STC弯曲性能相较常规浇筑明显提升;当纳米SiO_(2)掺量为2%时,抗弯强度、初始弯曲韧性比、残余弯曲韧性比分别增加38%、18%、40%。薄层夯倒下纤维分布较为集中,纤维的取向角在40°以内,而常规浇筑下纤维分布较为分散,取向角为20°~80°,说明薄层夯捣有利于纤维的定向分布。所提计算模型准确描述了抗弯强度和纤维取向之间的关系,实测值和计算值的误差小于6%。

基于Moldflow的模内装饰注射成型分析

介绍了模内装饰技术,以某一电子塑件为例,阐述了Moldflow软件模内装饰注射成型分析过程。通过与无薄膜塑件的分析比较,得出了模内装饰注射成型在充填、温度分布、翘曲等方面的特点,对模具设计和工艺有一定参考。

Analysis of Thermal Behavior for Beam Blank Continuous Casting Mold

Finite element models of steady heat conduction for cross section of beam blank mold were developed by using ABAQUS software. The effect of mold grinding thickness, cooling water velocity, diameter of restrietor rods and water channel design on hot face temperature was analyzed in detail. Attention was focused on the peak temperature and temperature uniformity along hot face. The results showed that the peak temperature of existing mold, about 337.2 ℃, is located in the fillet, and two valleys of hot face temperature are found in flange corner and junction of wide face and narrow face, respectively. Decreasing mold thickness, increasing cooling water velocity and increasing diameter of restrictor rods can all reduce peak temperature and improve temperature uniformity along hot race at the expense of lower overall temperature. Redesigning the water channel can decrease peak temperature and thermal gradient of mold without lowering overall temperature of hot face. In particular, the small hole design can improve temperature uniformity across hot face and obtain the best advantage.

Mathematical modeling of flow field in slab continuous casting mold considering mold powder and solidified shell with high temperature quantitative measurement

Optimization of mathematical model of flow field in slab continuous casting mold was performed by means of industrial measurement and mathematical modeling.The rod deflection method was used to quantitatively measure the velocities near the mold surface at high temperature.The measurement results were compared with the simulation results of three mathematical models at different argon gas flow rates of 6,10 and 14 L min^(−1).The model 1 neglects the mold powder layer,thermal effect and solidified shell.The model 2 only considers the influence of mold powder layer.The model 3 considers the influence of mold powder layer,thermal effect and solidified shell on the flow field.In all three models,the diameter of argon bubbles obeys Rosin-Rammler distribution fitted according to the experimental data of others’previous work.With increasing the argon gas flow rate,the velocity of liquid steel near the mold surface decreases.The model 1 seriously underestimates the shear stress of liquid steel near the mold surface,and its calculation results show higher velocity near the mold surface,lower turbulent kinetic energy and wider distribution of argon gas bubbles in the mold.The simulation results of model 2 only considering the viscous resistance of the mold powder layer to liquid steel makes the velocity near the surface lower than the measurement results obviously.The calculated velocities near the mold surface with model 3 are in best agreement with the measured results,showing the reasonable spatial distribution range of argon bubbles in the mold and the moderate turbulent kinetic energy.In the present conditions,the best argon gas flow rate is 10 L min^(−1) due to the moderate velocity near the mold surface,the appropriate distribution of argon gas bubbles in the mold and the smallest fluctuation amplitude on the mold surface.

鲜食葡萄电商悬固包装薄膜的力学性能分析与优化设计研究

目的针对电商物流包装存在操作繁琐、透气透湿不足、寄递中暴力分拣的问题以及葡萄易落粒损伤的特点,设计一种针对鲜食葡萄的透气透湿性适宜的简便化包装。方法采用激光打孔调整TPU薄膜透气透湿性,通过力学性能测试选出适宜厚度与孔隙排列方式,根据跌落试验确认TPU薄膜包裹葡萄的最佳凹陷程度,并验证悬固包装的有效性。结果厚度为0.08 mm、孔隙排列方式为Z形的TPU薄膜有优良的力学性能与透气透湿性,打孔后薄膜水蒸气透过率极显著提高(P<0.01),并且0.08 mm的Z形TPU薄膜凹陷3 cm的悬固包装在610 mm的高度跌落不触底,对葡萄的保护效果良好。纸浆模塑盒可承受400 N以上的力,循环压缩20次后仍有很好的支撑性,通过跌落测试可得悬固包装葡萄的表面损伤指数比袋中袋更小。结论综合来看,该悬固包装操作方便,打孔后透气透湿性显著提高,与包装箱匹配使用能满足堆码与运输要求,是一种符合包装运输要求的鲜食葡萄电商包装方式,本研究为果蔬类产品的电商包装结构设计提供了新思路。

基于动态决策最低水平线的多模台预制构件排布研究

针对离散空间的多模台上预制混凝土构件的排布问题,提出了动态决策最低水平线算法。首先,在传统构件排布目标函数的基础上,建立带出筋约束的构件排布优化模型。然后,设计动态评价因子和决策量化值,动态决策构件排入顺序和方向,实现对最低水平线算法的改进。最后,基于实际生产计划数据进行实验验证,实验结果表明,与人工经验、最低水平线算法、其他改进最低水平线算法相比,动态决策最低水平线算法可以更好地求解离散空间的多模台上预制混凝土构件排布问题,在单模台的最大利用率、平均模台利用率和模台数量方面均表现优异,有助于减少模台流转占用的生产时间,进而减少企业的生产成本。

无迹变异黏菌优化农产品物流配送中心选址算法

为降低物流配送成本,提高配送效率,提出一种混沌无迹变异黏菌优化算法求解农业物流配送中心选址问题。为提高算法搜索精度,设计Bernoulli混沌映射种群初始化方法,提高种群分布均匀性、多样性;引入精英动态引导兼顾算法搜索与开发平衡;设计随机无迹变异实现最优个体变异,协助种群跳离局部最优,以改进算法对农产品物流配送中心选址寻优。实验结果表明,改进算法能提升寻优效率和精度,配送成本比SMA降低了57.27%,效率提升了34.61%。

Effect of electropulsing treatment on solidification behavior of spring steels in a continuous casting mold simulator

An electropulsing-assisted mold simulator technique was developed to investigate the effects of a pulsed electric voltage on the quality of spring steels during continuous casting by analyzing the mold flux film,shell surface profile,shell micro-structure and inclusion distributions.The results revealed significantly increased crystallization fraction of the mold flux film from 61.2%to 75.3%and finer crystalline phase morphology in the case of electropulsing treatment.The surface of the initially solidified shell could be effectively healed,resulting in smoother shell surface profiles with higher pulsed voltage from 0 to 30V.Furthermore,an increase in the pulsed voltage from 0 to 30V resulted in finer dendritic structures during solidification with decreasing secondary dendrite arm spacing from the values of 17.6-32.2 to 9.7-15.0μm in the direction of shell side toward melt side.In addition,an area scan analysis of inclusions in the as-cast spring steel samples showed that the number of MnS inclusions in the size range of 2.0-4.0μm gradually decreased from 836 to 114 and the number of Al2O3 inclusions in the same size range decreased from 144 to 39,as the voltage increased from 0 to 30V.

Whole-process modeling of titanium disc forming for gradient distributions of temperature and deformation

Gradient distributions of temperature and deformation(GDTD)are crucial for achieving dual-performance discs of titanium alloys which is required by the service environment of aeroengine.However,heating,cooling and deforming sequence in the whole process of the titanium disc forming,which leads to difficulties for achieving GDTD due to a lot of parameters.To solve this problem,a whole-process model of the titanium disc forming for GDTD has been established.In the model,heating and cooling via heat radiation,conduction and convection,and deforming by local loading with mold chilling are all considered.Experiments on heating and cooling as well as deforming were carried out by using a furnace and the Gleeble-3500 machine.The experimental data are used to determine thermal parameters and constitutive relations of the IMI834 titanium alloy,and then to verify the reliability of the model.Then the model was used to simulate the evolution rules of temperature and deformation of the titanium disc.The results show that the heating surface,furnace temperature,billet profile and loading rate play the core role for the control of GDTD,and thus a set of parameters were determined.Therefore,this work provides a base for developing a new forming technology of the dual-performance titanium discs with the approach of local heating and local loading.

多策略改进的黏菌算法

针对求解复杂优化问题时,黏菌算法(SMA)存在全局搜索能力较弱、容易陷入局部最优值等问题,提出一种多策略融合的改进黏菌算法(TSMA)。首先,采用Logistic混沌映射来初始化黏菌个体的位置,增加种群的多样性提高算法的收敛速度;然后,融合萤火虫算法(FA),利用萤火虫自身的亮度和吸引度更新位置公式,增加种群在中期的探索和开发能力;最后,在算法迭代后期,引入T分布变异对最优解进行变异,从而提高种群跳出局部最优解的能力,提升寻优准确度。通过18个基准函数的测试,并与其他经典算法进行对比,结果表明,TSMA在搜索过程中明显优于其他算法,从而验证了对黏菌算法改进的有效性。

板坯连铸结晶器内温度/应力场耦合模型

考虑结晶器铜板中水槽的结构尺寸和分布、结晶器锥度对铸坯温度场和变形的影 响,建立了连铸结晶器内热和应力状态的有限元耦合分析模型。利用该模型模拟了结晶器内 钢水凝固过程温度分布和铜板的热机械变形,结果与实际符合较好.

长纤维增强聚合物注塑流动纤维取向分布数值模拟

基于Hele-Shaw流动模型及广义牛顿流体本构方程,采用ARD-RSC取向模型,建立了长纤维增强聚合物注塑成型流动数学模型。以方形薄板为研究对象,运用Moldflow对注塑流动过程进行模拟,研究注射时间、熔体温度、模具温度和保压压力对纤维取向及分布的影响。结果表明,注射时间对纤维取向的影响最为显著,随着注射时间延长,纤维取向值增加;随着熔体温度或模具温度的升高,纤维取向值减小;保压压力对纤维取向的影响与速度/压力转换点有关。